ES2926003T3 - An aerosol generating system and a cartridge for an aerosol generating system having a two-part liquid storage compartment - Google Patents

Abstract

The invention relates to a cartridge (100) for an aerosol generating system or an aerosol generating system. The cartridge or system comprises a storage compartment containing a liquid aerosol-forming substrate (131), the storage compartment having a first part (130) and a second part (135) connected together so that the liquid in the first part can pass into the second part, an airflow passage (140) passing between the first part and the second part of the storage compartment and a fluid-permeable aerosol generating element (120) located between the first part and the second part part of the storage compartment. The aerosol generating element has a first side and a second side opposite the first side, the first side of the aerosol generating element forming part of the airflow passage and the second side of the aerosol generating element being in contact with the liquid of the second storage compartment portion, such that the liquid aerosol-forming substrate in the first storage compartment portion must pass into the second storage compartment portion to reach the fluid-permeable aerosol-generating element. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

An aerosol generating system and a cartridge for an aerosol generating system having a two-part liquid storage compartment

The invention relates to an aerosol generating system and a cartridge for an aerosol generating system that is configured to heat a liquid aerosol-forming substrate to generate an aerosol. In particular, the invention relates to a portable aerosol generating system that is configured to generate aerosol for inhalation by the user.

In portable aerosol generating systems that generate an aerosol from an aerosol-forming liquid substrate, there is typically some means of transporting the liquid into the vicinity of an aerosol-generating element in order to replenish liquid that has been aerosolized by the aerosol generating element. However, it can be difficult to ensure that enough liquid is transported to the vicinity of the aerosol generating element without excess liquid supply, leading to leakage and inclusion of large liquid droplets in the aerosol that is inhaled by the user.

Document CN 203969207 U refers to an electronic cigarette with upper holes for injecting liquid and a lower component for exchanging and emitting heat. The electronic cigarette with the upper liquid injection holes and the lower heat exchange and emission component comprises a mouthpiece, a connection component, a liquid storage tube and a heat emission component.

Gravity can play a significant role in the transport of liquids within an aerosol generating system. Typically, the liquid is provided with a cartridge or cartomizer, which contains both the liquid and an aerosol-generating element in the form of a heating element. The cartridge has a mouth-side end through which the user draws the aerosol that is generated and a connection end opposite the mouth-side end that connects to a control unit containing control circuitry and a energy supply. The heating element is typically located near the connection end to allow easy connection to the power supply, with the liquid being held in a storage compartment between the heating element and the muzzle-side end of the cartridge. During typical use of this type of system, the highest part of the system is the mouth-side end of the cartridge, so gravity acts to pull the liquid down toward the heater. This can result in excess liquid delivery to the heating element and in particular liquid leakage into the airflow path through which the aerosol is delivered to the user.

An alternative arrangement is to position the heating element higher than the liquid storage compartment during typical use, and use a capillary material to supply liquid to the heater against the force of gravity. But this can lead to an insufficient or inconsistent supply of liquid to the heating element particularly as the liquid storage compartment empties.

It would be desirable to provide an arrangement for an aerosol generating system in which an adequate and constant supply of liquid is provided to the aerosol generating element even as the liquid storage compartment empties, while minimizing liquid leakage, and in which complicated components such as pumps are not required.

The invention is defined in the appended independent claims, to which reference should now be made. Preferred or advantageous features of the invention are defined in the dependent subclaims. Aspects, embodiments, or examples that fall outside the scope of the appended independent claims are not part of the invention, and are included for illustrative or explanatory purposes only.

In a first aspect, there is provided a cartridge for an aerosol generating system, the cartridge comprising:

a storage compartment containing an aerosol-forming liquid substrate, the storage compartment having a first portion and a second portion that are interconnected such that liquid in the first portion can flow into the second portion;

an air flow passage passing between the first portion and the second portion of the storage compartment;

a fluid-permeable aerosol-generating element that is positioned between the first portion and the second portion of the storage compartment and that has a first side and a second side opposite the first side, the first side of the aerosol-generating element forming part of the airflow passage and the second side of the aerosol generating element that is in contact with the liquid in the second portion of the storage compartment, so that the aerosol-forming liquid substrate in the first portion of the storage compartment can reaching the fluid permeable aerosol generating element only through the second portion of the storage compartment.

The first portion and the second portion are connected to each other by a liquid channel so that the liquid in the first portion can pass to the second portion through the liquid channel.

The aerosol generating element may be a heating element. Alternatively, the aerosol generating element may be a vibrating element.

Advantageously, the first portion of the storage compartment has a greater liquid storage capacity than the second portion of the storage compartment. Advantageously, the first portion of the storage compartment is larger than the second portion of the storage compartment. In use, the first portion of the storage compartment is typically positioned above the aerosol generating element. Having the first storage compartment portion larger than the second storage compartment portion ensures that liquid is delivered from the first storage compartment portion to the second storage compartment portion, and thus to the aerosol generating element, during its use, under the influence of gravity.

Advantageously, the second portion of the storage compartment contains a capillary material in contact with the second side of the aerosol generating element. The capillary material supplies aerosol-forming liquid substrate to the aerosol-generating element against the force of gravity. By requiring the aerosol-forming liquid substrate to move against the force of gravity during use to reach the aerosol-generating element, the possibility of large droplets of the liquid entering the airflow passage is reduced.

The capillary material may be made of a material capable of ensuring that there is liquid aerosol-forming substrate in contact with at least a portion of the surface of the aerosol-generating element. The capillary material may extend into the interstices or openings in the aerosol generating element. The aerosol-generating element can draw aerosol-forming liquid substrate into the interstices or openings by capillary action.

A capillary material is a material that actively transports liquid from one end of the material to another. The capillary material may have a fibrous or spongy structure. The capillary material preferably comprises an array of capillaries. For example, the capillary material may comprise a plurality of fine gauge fibers or threads or other tubes. The fibers or yarns may be generally aligned to transport the aerosol-forming liquid substrate toward the aerosol-generating element. Alternatively, the capillary material may comprise a sponge-like or foam-like material. The structure of the capillary material forms a plurality of small holes or tubes, through which the aerosol-forming liquid substrate can be transported by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials are a sponge or foam material, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic material, a fibrous material, for example, made from spun or extruded fibers, such such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon or ceramic fibers. The capillary material can have any capillarity and porosity suitable for use with different physical properties of the liquid. The liquid aerosol-forming substrate has physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that allow the liquid aerosol-forming substrate to be transported through capillary medium by capillary action.

Alternatively or additionally, the storage compartment may contain a carrier material for containing an aerosol-forming liquid substrate. The carrier material may be in the first storage compartment portion, the second storage compartment portion, or in both the first and second storage compartment portions. The carrier material can be a foam and a fiber collection sponge. The carrier material can be formed from a polymer or copolymer. In one embodiment, the carrier material is a spun polymer. The aerosol-forming substrate can be released into the carrier material during use. For example, the aerosol-forming liquid substrate may be provided in a capsule.

The cartridge may comprise a housing having a connection end and a muzzle end remote from the connection end, the connection end being configured to connect to a control body of an aerosol generating system. The second side of the aerosol generating element may face the connection end and the first side of the aerosol generating element may face the mouth side end. Electrical power may be supplied to the aerosol generating element from a control body which is connected through the connection end of the housing.

Advantageously, the aerosol-generating element is closer to the connection end than to the mouth-side end opening. This allows a simple and short electrical connection path between a power source in the control body and the aerosol generating element.

The air flow passageway extends between the first and second portions of the storage compartment. Additionally, the airflow passageway may extend through the first portion of the storage compartment. For example, the first portion of the storage compartment may have an annular cross-section, with the airflow passageway extending from the aerosol generating element to a opening of the end of the mouth side through the first portion of the storage compartment. Alternatively, the airflow passageway may extend from the aerosol generating element to the mouthside end opening adjacent the first portion of the storage compartment.

The first and second sides of the aerosol generating element may be substantially flat. The aerosol generating element may be a heating element. The heating element may comprise a substantially flat heating element to allow easy manufacture. Geometrically, the term "substantially planar" heating element is used to refer to the heating element that is in the form of a substantially two-dimensional topological manifold. Thus, the substantially flat heating element extends in two dimensions across a surface substantially more than in a third dimension. In particular, the dimensions of the substantially flat heating element in the two dimensions within the surface are at least five times larger than in the third dimension, normal to the surface. An example of a substantially flat heating element is a structure between two substantially imaginary parallel surfaces, where the distance between these two imaginary surfaces is substantially smaller than the extent within the surfaces. In some embodiments, the substantially planar heating element is planar. In other embodiments, the substantially flat heating element is curved along one or more dimensions, eg, forming a dome or bridge shape.

The heating element may comprise a plurality of gaps or openings extending from the second side to the first side and through which fluid may pass.

The aerosol generating element may alternatively or additionally comprise a vibrating membrane or mesh. A piezoelectric element can be used to vibrate the membrane or mesh. The aerosol-forming liquid substrate passing through the openings or interstices in the vibrating membrane or mesh can form droplets that form an aerosol in an airflow through the system. The aerosol generating element may alternatively, or additionally, comprise a plurality of droplet ejectors, such as bubble jet nozzles which may use a piezoelectric or thermal ejection mechanism.

The heating element may comprise a plurality of electrically conductive filaments. The term "filament" is used throughout the description to refer to an electrical path disposed between two electrical contacts. A filament can arbitrarily branch and diverge into several paths or filaments, respectively, or it can converge from several electrical paths into one path. A filament can have a round, square, flat, or any other cross section. A filament can be arranged in a straight or curved manner.

The heating element may be a series of filaments, for example arranged parallel to each other. Preferably, the filaments can form a mesh. The mesh can be woven or non-woven. The mesh can be formed by using different types of weave or lattice structures. Alternatively, the electrically conductive heating element consists of a series of filaments or a fabric of filaments. The mesh, array or fabric of electrically conductive filaments may further be characterized by its ability to retain liquids.

In a preferred embodiment, a substantially flat heating element may be constructed of a wire that is formed into a wire mesh. Preferably, the mesh has a flat weave design. Preferably, the heating element is a wire mesh made of a mesh-like strip.

The electrically conductive filaments may define gaps between the filaments and the gaps may be between 10 microns and 100 microns wide. Preferably the filaments give rise to capillary action in the interstices so that, during use, liquid that vaporizes is drawn into the interstices, increasing the area of contact between the heating element and the liquid substrate forming the filaments. aerosol.

The electrically conductive filaments can form a mesh size between 60 and 240 filaments per centimeter (+/- 10 percent). Preferably, the mesh density is between 100 and 140 filaments per centimeter (+/- 10 percent). More preferably, the mesh density is about 115 filaments per centimeter. The width of the gaps can be between 100 microns and 25 microns, preferably between 80 microns and 70 microns, more preferably about 74 microns. The percentage of open area of the mesh, which is the ratio of the area of the interstices to the total area of the mesh, can be between 40 percent and 90 percent, preferably between 85 percent and 80 percent, more preferably approximately. 82 percent.

The electrically conductive filaments may have a diameter between 8 microns and 100 microns, preferably between 10 microns and 50 microns, more preferably between 12 microns and 25 microns, and most preferably about 16 microns. The filaments may have a round cross section or may have a flattened cross section.

The area of the mesh, array, or fabric of electrically conductive filaments may be small, for example, less than or equal to 50 square millimeters, preferably less than or equal to 25 square millimeters, with greater preferably about 15 square millimeters. The size is chosen such that it incorporates the heating element within a portable system. An electrically conductive mesh, array, or filament fabric size of less than or equal to 50 square millimeters reduces the total amount of energy required to heat the electrically conductive mesh, array, or filament fabric while still being heated. ensures sufficient contact of the electrically conductive filament mesh, array or fabric with the aerosol-forming liquid substrate. The mesh, array or fabric of electrically conductive filaments may, for example, be rectangular and have a length of between 2 millimeters to 10 millimeters and a width of between 2 millimeters and 10 millimeters. Preferably, the mesh has dimensions of approximately 5 millimeters by 3 millimeters.

The heating element filaments may be formed of any material with suitable electrical properties. Suitable materials include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made from a material ceramic and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals.

Examples of suitable metal alloys include stainless steel, constantan, nickel-, cobalt-, chromium-, aluminium-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, alloys containing gallium, manganese and iron, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, alloys based on iron-aluminum and alloys based on iron-manganese-aluminum. Timetal® is a registered trademark of Titanium Metals Corporation. The filaments may be coated with one or more insulators. Preferred materials for the electrically conductive filaments are stainless steel and graphite, most preferably 300 series stainless steel such as AISI 304, 316, 304L, 316L. Additionally, the electrically conductive heating element may comprise combinations of the above materials. A combination of materials can be used to improve resistance control of the substantially flat heating element. For example, materials with a high intrinsic resistance can be combined with materials with a low intrinsic resistance. This can be advantageous if one of the materials is more beneficial from other perspectives, for example, price, machinability, and other physical and chemical parameters. Advantageously, a substantially flat filament arrangement with increased strength reduces parasitic losses. Advantageously, high resistivity heaters allow more efficient use of battery power.

Preferably, the filaments are made of wire. More preferably the wire is made of metal, most preferably it is made of stainless steel.

The electrical resistance of the electrically conductive filament mesh, array or fabric of the heating element may be between 0.3 Ohm and 4 Ohm. Preferably, the electrical resistance is equal to or greater than 0.5 Ohms. More preferably, the electrical resistance of the electrically conductive filament mesh, array or fabric is between 0.6 Ohm and 0.8 Ohm, and most preferably about 0.68 Ohm. The electrical resistance of the electrically conductive mesh, array or web of filaments is preferably at least one order of magnitude, and more preferably at least two orders of magnitude, greater than the electrical resistance of the electrically conductive contact areas. This ensures that the heat generated by the passage of current through the heating element is located in the mesh or series of electrically conductive filaments. It is advantageous to have a low overall resistance for the heating element if the system is powered by a battery. A low resistance, high current system allows high energy delivery to the heating element. This allows the heating element to rapidly heat the electrically conductive filaments to the desired temperature.

Alternatively, the heating element may comprise a heating plate in which a series of openings are formed. The openings can be formed by engraving or machining, for example. The plate may be formed from any material with suitable electrical properties, such as the materials described above in connection with the filaments of a heating element.

The first side of the aerosol generating element may face directly toward the mouthside end opening. This orientation of a flat aerosol generating element allows for easy assembly of the cartridge during manufacture.

The heating element may be part of a heating unit. The heating unit may comprise the heating element and electrical contact portions, which are electrically connected to the heating element. The electrical contact portions may be two electrically conductive contact pads. Electrically conductive contact pads may be positioned in an edge area of the heating element. Preferably, the at least two electrically conductive contact pads can be positioned at the ends of the heating element. An electrically conductive contact pad can be attached directly to the electrically conductive filaments of the heating element. An electrically conductive contact pad may comprise a tin patch.

Alternatively, an electrically conductive contact pad may be integral with the heating element.

The contact portions may be exposed through a connection end of the housing to allow contact with electrical contact pins in a control body of an aerosol generating system.

The storage compartment may comprise a storage compartment housing. The aerosol generating element can be fixed to the housing of the storage compartment. The storage compartment housing may comprise a molded component or heater support, the molded component or heater support being molded onto the heating unit or other form of aerosol generating element. The molded portion or heater support may cover a portion of the first side of the heating unit or aerosol generating element to isolate the electrical contact portions of the airflow passage and may cover at least a portion of the second side of the heater. the heating unit or the aerosol generating element for isolating the electrical contact portions of the liquid aerosol-forming substrate.

The heater support may comprise at least one wall extending from the second side of the heating unit, the at least one wall forming part of the second portion of the liquid storage compartment. The heater support may define a liquid flow path from a first side of the heating unit to a second side of the heating unit.

The liquid storage compartment may contain aerosol-forming liquid substrate. As used herein, with reference to the present invention, an aerosol-forming substrate is a substrate capable of releasing volatile compounds that can form an aerosol. Volatile compounds can be released by heating the aerosol-forming substrate. Volatile compounds can be released by moving the aerosol-forming substrate through the passageways of a vibrating element.

The aerosol-forming substrate may be a liquid at room temperature. The aerosol-forming substrate can comprise both solid and liquid components. The aerosol-forming liquid substrate may comprise nicotine. The liquid nicotine-containing aerosol-forming substrate may be a nicotine salt matrix. The aerosol-forming liquid substrate may comprise material of plant origin. The aerosol-forming liquid substrate may comprise tobacco. The liquid aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco-flavored compounds, which are released from the aerosol-forming substrate upon heating. The aerosol-forming liquid substrate may comprise homogenized tobacco material. The aerosol-forming liquid substrate may comprise a non-tobacco-containing material. The aerosol-forming liquid substrate may comprise homogenized plant-derived material.

The aerosol-forming liquid substrate may comprise one or more aerosol formers. An aerosol former is any suitable and known compound or mixture of compounds which, in use, facilitates the formation of a stable, dense aerosol and which is substantially resistant to thermal degradation at the operating temperature of the system. Examples of suitable aerosol formers include glycerin and propylene glycol. Suitable aerosol formers are well known in the art and include, but are not limited to: polyhydric alcohols, such as triethylene glycol, 1,3-butanoidol, and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol-forming liquid substrate may comprise water, solvents, ethanol, plant extracts, and natural or artificial flavors.

The aerosol-forming liquid substrate may comprise nicotine and at least one aerosol former. The aerosol former can be glycerin or propylene glycol. The aerosol former can comprise either glycerin or propylene glycol. The aerosol-forming liquid substrate may have a nicotine concentration of between about 0.5% and about 10%, eg, about 2%.

The housing may be formed of a moldable plastic material, such as polypropylene (PP) or polyethylene terephthalate (PET). The housing may form part or all of a wall of the storage compartment. The housing and the storage compartment can be integrally formed. Alternatively, the storage compartment may be formed separately from the housing and assembled to the housing.

The cartridge may comprise a removable mouthpiece through which the user can draw the aerosol. The detachable mouthpiece can cover the mouth side end opening. Alternatively, the cartridge may be configured to allow a user to draw directly onto the mouthside end opening.

The cartridge may be refillable with liquid aerosol-forming substrate. Alternatively, the cartridge may be designed to be discarded when the storage compartment is emptied of liquid aerosol-forming substrate.

In a second aspect, there is provided a cartridge for an aerosol generating system, the cartridge comprising:

a housing having a mouth-side end opening;

a storage compartment within the housing and containing an aerosol-forming liquid substrate;

a fluid-permeable aerosol-generating element within the housing and having a first side and a second side opposite the first side, the first side of the aerosol-generating element being closer to the mouthside end opening than the second side of the aerosol generating element, and the second side of the aerosol generating element is in contact with the liquid in the storage compartment; Y

an airflow passageway extending from the first side of the aerosol generating element to the mouthside end opening;

wherein a first storage compartment portion is positioned between the aerosol generating element and the mouthside end opening and a second storage compartment portion is positioned on an opposite side of the aerosol generating element from the mouthside opening. end of the side of the mouth.

In this context "positioning between" means that a straight line from the aerosol generating element to the mouthside end opening must pass through the first portion of the storage compartment. The air flow passage may pass through the storage portion.

The cartridge features of the first aspect can be applied to the second aspect.

In a third aspect there is provided an aerosol generating system comprising a cartridge according to the first or second aspect and a control body which is connected to the cartridge, the control body being configured to control an electrical power supply to the element. aerosol generator.

The control body may comprise at least one electrical contact element that is configured to provide an electrical connection to the aerosol generating element when the control body is connected to the cartridge. The electrical contact element may be elongated. The electrical contact element can be spring loaded. The electrical contact element may contact an electrical contact pad on the cartridge.

The control body may comprise a connection portion for engagement with the connection end of the cartridge.

The control body may comprise a power supply.

The control body may comprise control circuitry that is configured to control the power supply from the power supply to the aerosol generating element.

The control circuitry may comprise a microcontroller. The microcontroller is preferably a programmable microcontroller. The control circuits may comprise other electronic components. The control circuitry may be configured to regulate a power supply to the aerosol generating element. Power may be supplied to the aerosol generating element continuously after activation of the system or may be supplied intermittently, such as on a puff-by-puff basis. Power may be supplied to the aerosol generating element in the form of pulses of electrical current.

The control body may comprise a power supply which is arranged to supply power to at least one of the control systems and the aerosol generating element. The aerosol generating element may comprise an independent power supply. The aerosol generating system may comprise a first power supply that is arranged to supply power to the control circuit and a second power supply that is configured to supply power to the aerosol generating element.

The power supply may be a DC power supply. The power supply can be a battery. The battery may be a lithium-based battery, for example, a lithium cobalt, lithium iron phosphate, lithium titanate or lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power supply may be another form of charge storage device, such as a capacitor. The power supply may require recharging and be configured for many charge and discharge cycles. The power supply may have a capacity that allows sufficient power storage for one or more user experiences; for example, the power supply may have sufficient capacity to allow continuous aerosol generation for a period of about six minutes, which corresponds to the typical time it takes to smoke a conventional cigarette, or for a period that is a multiple of six minutes. In another example, the power supply may have sufficient capacity to allow a predetermined number of puffs or discrete activations of the atomization unit.

The aerosol generating system may be a portable aerosol generating system. The portable aerosol generating system may be configured to allow a user to suck on a mouthpiece to draw an aerosol through the mouthside end opening. The aerosol generating system may be comparable in size to a conventional tobacco or cigarette. The aerosol generating system can have an overall length of between about 30mm and about 150mm. The aerosol generating system can have an external diameter of between about 5 mm and about 30 mm.

Although the system of the invention has been described as comprising a cartridge and a control body, it is possible to implement the invention in a single piece system. In a fourth aspect, an aerosol generating system is provided, comprising:

a housing having an air inlet and a mouth-side end opening;

a storage compartment within the housing containing an aerosol-forming liquid substrate, the storage compartment having a first portion and a second portion that are interconnected such that liquid in the first portion can pass into the second portion;

an air flow passage passing from the air inlet between the first portion and the second portion of the storage compartment to the mouthside end opening;

a fluid-permeable aerosol-generating element that is positioned between the first portion and the second portion of the storage compartment and that has a first side and a second side opposite the first side, the first side of the aerosol-generating element forming part of the airflow passage and the second side of the aerosol generating element that is in contact with the liquid in the second portion of the storage compartment, so that the aerosol-forming liquid substrate in the first portion of the storage compartment must passing into the second portion of the storage compartment to reach the fluid permeable aerosol generating element.

a power supply within the housing that connects to the aerosol generating element; and a control circuit within the housing and configured to control the power supply from the power supply to the aerosol generating element.

In a fifth aspect, an aerosol generating system is provided, comprising:

a housing having a mouth-side end opening;

a storage compartment within the housing and containing an aerosol-forming liquid substrate;

a fluid-permeable aerosol-generating element within the housing and having a first side and a second side opposite the first side, the first side of the aerosol-generating element being closer to the mouthside end opening than the second side of the aerosol generating element, and the second side of the aerosol generating element is in contact with the liquid in the storage compartment;

an airflow passageway extending from the first side of the aerosol generating element to the mouthside end opening;

a power supply within the housing that connects to the aerosol generating element; and a control circuit within the housing and configured to control the power supply from the power supply to the aerosol generating element;

wherein a first storage compartment portion is positioned between the aerosol generating element and the mouthside end opening and a second storage compartment portion is positioned on an opposite side of the aerosol generating element from the mouthside opening. end of the side of the mouth.

The aerosol generating element may be generally flat. The second side of the aerosol generating element can be positioned outside the airflow passage. The second side of the aerosol generating element may be in contact with the liquid in the storage compartment, but not in contact with the air in the air flow passage.

The first portion of the storage compartment and the second portion of the storage compartment are connected to each other by a liquid channel so that the liquid in the first portion can pass into the second portion through the liquid channel. The aerosol generating element of the fourth and fifth aspects may comprise any of the features of the aerosol generating element described in relation to the first and second aspects.

The storage compartment of the fourth and fifth aspects may comprise any of the features of the storage compartment described in relation to the first and second aspects. The storage compartment may be refillable with liquid aerosol-forming substrate. Alternatively, the system can be designed to be discarded when the storage compartment is emptied of aerosol-forming liquid substrate.

In the fourth and fifth aspects, the housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composite materials containing one or more of those materials, or thermoplastics that are suitable for food or pharmaceutical applications, for example, polypropylene, polyetheretherketone (PEE ^k ), and polyethylene. The material can be light and not brittle. The housing may comprise any of the housing features described in relation to the first aspect.

The airflow passageway of the fourth and fifth aspects may comprise any of the features of the airflow passageway described in relation to the first and second aspects.

The power supply of the fourth and fifth aspects may comprise any of the features of the power supply described in relation to the third aspect.

The control circuitry of the fourth and fifth aspects may comprise any of the features of the control circuitry described in connection with the third aspect.

The cartridge, control body or aerosol generating system in any of the aspects may comprise a puff detector in communication with the control circuitry. The puff detector can be configured to detect when a user draws through the airflow passage.

The cartridge, control body or aerosol generating system in any of the aspects may comprise a temperature sensor in communication with the control circuitry. The cartridge, control body, or aerosol generating system may comprise a user input, such as a switch or button. User input may allow a user to turn the system on and off.

The cartridge, control body, or aerosol generating system may further comprise indicating means for indicating to a user the particular amount of aerosol-forming liquid substrate that is held in the liquid storage portion. The control circuitry may be configured to activate the indicating means after a determination has been made of the amount of aerosol-forming liquid substrate remaining in the liquid storage portion.

The indicating means may comprise one or more lights, such as light-emitting diodes (LEDs), a display, such as an LCD display, and acoustic indicating means, such as a loudspeaker or buzzer, and vibrating means. The control circuits can be configured to illuminate one or more of the lights, display a quantity on the screen, sound through the speaker or buzzer, and vibrate the vibrating media.

Characteristics of one aspect can be applied to the other aspects.

Embodiments of the invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic illustration of an aerosol generating system in accordance with the invention; Figure 2a is a schematic illustration of a first cross-section of a cartridge, including a mouthpiece, in accordance with the invention;

Figure 2b is a schematic illustration of a second cross section of a cartridge according to the invention;

Figure 3 illustrates a cartridge without a mouthpiece;

Figures 4a and 4b illustrate the heater support of Figures 3a and 2b and Figure 3;

Figures 5a and 5b are top perspective views of the heating unit and heater support of Figures 4a and 4b;

Figures 6a and 6b are bottom views of the heating unit and heater support of Figures 4a and 4b; Y

Figure 7 illustrates the electrical connection of a control body to the heating unit.

Figure 1 is a schematic illustration of an aerosol generating system in accordance with the invention. The system comprises two main components, a cartridge 100 and a control body 200. A connection end 115 of cartridge 100 removably connects to a corresponding connection end 205 of control body 200. Control body 200 contains a battery 210, which in this example is a rechargeable lithium ion battery, and control circuitry 220. Aerosol generating device 10 is portable and comparable in size to a conventional tobacco or cigarette.

Cartridge 100 comprises a housing 105 containing an atomization unit 120 and a liquid storage compartment having a first portion 130 and a second portion 135. An aerosol-forming liquid substrate is held in the liquid storage compartment. Although not illustrated in Figure 1, the first portion 130 of the liquid storage compartment is connected to the second portion 135 of the liquid storage compartment so that the liquid in the first portion 130 can pass into the liquid storage compartment. second portion 135. Atomization unit 120 receives liquid from second portion 135 of the liquid storage compartment. In this embodiment, the atomizing unit 120 is a generally flat fluid permeable heating unit.

An airflow passage 140, 145 extends through the cartridge 100 from an air inlet 150 beyond the spray unit 120 and from the spray unit 120 to a mouth-side end opening 110 in the cartridge housing 105.

The components of the cartridge 100 are arranged so that the first portion 130 of the liquid storage compartment is located between the atomizing unit 120 and the mouthside end opening 110, and the second portion 135 of the liquid storage compartment. liquid is positioned on an opposite side of the atomizing unit 120 to the mouth-side end opening 110. In other words, the atomizing unit 120 is located between the two portions 130, 135 of the liquid storage compartment and it receives liquid from the second portion 135, and the first portion 130 of the liquid storage compartment is closer to the mouthside end opening 110 than the second portion 135 of the liquid storage compartment. The airflow passageway extends beyond the atomizing unit 120 and between the first and second portions 130, 135 of the liquid storage compartment.

The system is configured such that a user can take a puff or suck on the mouthside end opening 110 of the cartridge 100 to draw aerosol into their mouth. In operation, when a user takes a puff at the mouth-side end opening 110, air is sucked through the airflow passage from the air inlet 150, past the atomizing unit 120, to the mouthside end opening 110. Control circuitry 220 controls the supply of electrical power from battery 210 to cartridge 100 when the system is activated. This in turn controls the amount and properties of the vapor that is produced by the atomizing unit 120. The control circuit 220 may include an airflow sensor and the control circuit 220 may supply electrical power to the atomizing unit. 120 when the airflow sensor detects the user's puffs on the cartridge 100. This type of control arrangement is well established in aerosol generating systems such as inhalers and electronic cigarettes. Therefore, when a user draws on the mouth-side end opening 110 of the cartridge 100, the atomization unit 120 is activated and generates a vapor that is entrained in the airflow passing through the airflow passage. 140. The vapor is cooled by the airflow in passage 145 to form an aerosol, which is then sucked into the user's mouth through the mouthside end opening 110.

In operation, the mouthside end opening 110 is typically the highest point of the device. The construction of the cartridge 100, and in particular the arrangement of the atomization unit 120 between the first and second portions 130, 135 of the liquid storage compartment, is advantageous in that it takes advantage of gravity to ensure that the liquid substrate is delivered to the atomizing unit 120 even as the liquid storage compartment empties, but avoid over-supplying liquid to the atomizing unit 120 which may lead to liquid leakage in the airflow passage 140.

Figure 2 is a first cross section of a cartridge according to one embodiment of the invention. Figure 2b is a second cross section, orthogonal to the cross section of Figure 2a.

The cartridge 100 of Figures 2a comprises an outer housing 105 having a muzzle end with a muzzle end opening 110, and a connecting end opposite the muzzle end. Within the housing 105 is the liquid storage compartment containing an aerosol-forming liquid substrate 131. The liquid is contained in the liquid storage compartment by three components, an upper storage compartment housing 137, a heater bracket 134 and an end cap 138. A heating unit 120 is held in the heater support 134. A capillary material 136 is provided in the second portion 135 of the liquid storage compartment, and adjoins the heating element in a central region. of heating unit 120. The capillary material is oriented to transport liquid to the heating element. The heating element 121 comprises a mesh heating element, which is formed from a plurality of filaments. Details of this type of heating element construction can be found in WO2015/117702 for example. The air flow passage 140 extends between the first and second portions 130, 135 of the liquid storage compartment. A bottom wall of the airflow passage 140 comprises the heater element 121 and heater support 134, side walls of the airflow passage 140 comprise portions of the heater support 134, and an upper wall of the airflow passage 140 comprises a portion of the upper storage compartment housing 137. The airflow passage 130 has a vertical portion 145 extending through the first portion 130 of the liquid storage compartment, as shown in Figure 2a, towards the mouth-side end opening 110.

The heating unit 20 is generally flat and has two faces. A first face of the heating unit 120 faces the first portion 130 of the liquid storage compartment and the mouth-side end opening 110. A second face of the heating unit 120 is in contact with the material. capillary 136 and liquid 131 in the liquid storage compartment, and is oriented towards a connection end 115 of the cartridge 100. The heating unit 120 is located closer to the connection end such that the electrical connection of the heating unit 120 to a power supply can be achieved easily and robustly, as will be described. The first portion 130 of the liquid storage compartment is larger than the second portion 135 of the liquid storage compartment and occupies a space between the heating unit 120 and the mouth-side end opening 110 of the cartridge 100. The liquid in the first portion 130 of the liquid storage compartment can move to the second portion 135 of the liquid storage compartment through the liquid channels 133 on either side of the heating unit 120. In this example two channels are provided for provide a symmetrical structure, although only one channel is necessary. The channels are closed liquid flow paths defined between the upper storage compartment housing 137 and the heater support 134.

Figure 3 is an enlarged view of the liquid storage compartment and heating unit 120 of the cartridge 100 shown in Figures 2a and 2b. It is possible to provide a cartridge comprising the components shown in Figure 3, without an external housing 105 or mouthpiece. A mouthpiece may be provided as a separate component of cartridge 100 or perhaps provided as part of control body 200, with a cartridge as shown in Figure 3 being configured to insert into control body 200.

The cartridge 100 shown in Figure 3 can be assembled by first molding the heater support 134 around the heating unit 120. The heating unit comprises a mesh heating element 122 as described, which is attached to a pair of tin contact pads 121, which have a much lower electrical resistivity than heating element 122. Contact pads 121 are attached to opposite ends of heating element 122, as illustrated in Figures 6a and 6b. The heater support 134 is then attached to the upper storage portion housing by the use of welding or adhesive. Capillary material 136 is inserted into the second portion 135 of the liquid storage compartment. End cap 138 is then attached to the heater bracket to seal the liquid storage compartment.

Alternatively, the capillary material of heater support 136 and end cap 138 may be assembled first before being attached to the upper storage portion housing. Figure 4a is a first cross section of heating unit 120, heater support 134, capillary material 136, and end cap 138. Liquid channels 133 are clearly shown. Figure 4b is a second cross-section of heating unit 120, heater support 134, capillary material 136, and end cap 138. It can be seen that heater support 134 secures heating unit 120 on both sides of the heater. heating unit 120. Contact pads 121 are easily accessible from the second side of heating unit 120 but are covered by the heater bracket on the first side of heating unit 120 to protect them from steam in the passageway. of air flow 140. A bottom wall of heater support 134 extends from the second side of heating unit 120 and isolates contact pads 121 from liquid in second portion 135 of the liquid storage compartment.

Heater support 134 and heating unit 120 are shown in more detail in Figures 5a, 5b, 6a and 6b. Figures 5a and 5b are top perspective views of the heating unit 120 and heater support 134 of Figures 4a and 4b. Figures 6a and 6b are bottom views of the heating unit 120 and heater support 134 of Figures 4a and 4b. End cap 138 and capillary material 136 are removed.

Figures 5a and 5b show the cover surfaces 160 of the heater support 134 covering the first side of the contact portions 121 of the heating unit 120, while the mesh heater element 122 is exposed. The liquid channels 133 from the first liquid storage compartment portion 130 to the second liquid storage compartment portion 135 are defined by the vertical walls of the heater support 134. The same walls also join the air flow passage 140 as it passes over heating element 120.

The heater bracket is injection molded and formed from an engineering polymer, such as polyetheretherketone (PEEK) or LCP (liquid crystal polymer).

Figures 6a and 6b show how heater support 134 isolates contact pads 121 from second portion 135 of the liquid storage compartment, but allows contact pads 121 to be accessible. A wall of the heater support 134 isolates the contact portions 121 from the liquid in the storage portion. Heater support 134 also isolates the exposed portion of contact pads 121 from airflow passage 140.

Overmolding of heater support 134 into heating unit 120 provides a robust component that can be easily handled during system assembly without damaging delicate portions of heater element 134.

Liquid can be inserted into the liquid storage compartment from the lower end, before end cap 138 is attached, or through a fill port (not shown) in the reservoir portion housing. top storage, after end cap 138 is attached. The liquid storage compartment may be refillable through a fill port.

The liquid storage compartment can then be attached within a cartridge housing 105 by use of mechanical attachment or by use of other means, such as adhesive or welding, for example. Alternatively, the storage compartment may be releasably attached or attached to the housing of a control body of an aerosol generating system.

Figure 7 illustrates how the electrical contacts on a control body of an aerosol generating system can be arranged to mate with the exposed contact pads of the heating unit 120. Only the electrical contacts of the control body 200 are shown. Electrical components comprise a pair of spring-loaded pins 160 that extend into slots formed on either side of heater mount 134 to contact contact pads 121. With this arrangement, cartridge 100 can be inserted or attached to the heater. control body 200 by moving the cartridge 100 in contact with the pins in an insertion direction parallel to the longitudinal axis of the pins. When the pins are in contact with contact pads 121, electrical current may be supplied to heating element 122. Cartridge 100 may be retained within a housing in the control body or may be attached to the control body by use of a push fitting or a snap fitting.

Figure 7 also shows a cut away portion of the upper storage compartment housing 137. It can be seen that an internal wall 139 is used to divide the air flow passage 145 of the liquid 131 with the liquid storage compartment. The air inlet 150 is also clearly illustrated.

The operation of the system will now be briefly described. The system is first turned on by use of a switch on control body 200 (not shown in Figure 1). The system may comprise an airflow sensor in fluid communication with the puff-activatable airflow passageway. This means that control circuitry 220 is configured to supply power to heating element 122 based on signals from the airflow sensor. When the user wishes to inhale aerosol, the user takes a puff at the mouthside end opening 110 of the system. Alternatively, the power supply to heating element 122 may be based on user actuation of a switch. When power is supplied to the heating element 122, the heating element 122 is heated to a temperature above a vaporization temperature of the aerosol-forming liquid substrate 131. The aerosol-forming liquid substrate 131 that is lost to the heating element 122 vaporizes in this way and escapes into airflow passage 140. The mixture of air sucked through air inlet 150 and steam from heating element 122 is sucked through airflow passage 140 , 145 toward the mouthside end opening 110. As it travels through the airflow passage 140, 145 the vapor cools to form an aerosol, which is then drawn into the user's mouth. At the end of the user's puff or after a set period of time, power to the heating element 122 is removed and the heater cools again before the next puff.

During normal use in this manner, and between puffs by the user, the system is typically held so that the mouthside end of the system is higher. This means that the first portion 130 of the liquid storage compartment is above the second portion 135 of the liquid storage compartment, and the heating element is above the capillary material 136 in the second portion 135 of the storage compartment. liquid storage. As the liquid in the capillary material 136 near the heating element 122 vaporizes and escapes into the air flow passage 140, it is replenished by the liquid in the first portion 130 of the liquid storage compartment flowing into the capillary material. 136 under the influence of gravity. The liquid from the first portion 130 flows through the two closed liquid flow paths 133 into the capillary material 136. The capillary material 136 then draws the liquid to the heating element 122 ready for the user's next puff. The direction of liquid travel is illustrated by the arrows in Figure 2a.

Although the invention has been described in relation to a system comprising a separate but connectable control body and cartridge, it should be clear that the arrangement of the heater support molded into the heating unit, and the configuration of the liquid storage compartment , the airflow passage and heating unit can be used in a one-piece aerosol generating system.

It should also be clear that alternative geometries are possible within the scope of the invention. In particular, the air flow passage may extend through the first portion of the storage compartment in a different manner, such as through a center of the liquid storage compartment. The cartridge and liquid storage compartment may have a different cross-sectional shape and the heating unit may have a different shape and configuration.

An aerosol generating system having the construction described has several advantages. The possibility of liquid leakage into the air flow passage is reduced by the arrangement of the first and second portions of the liquid storage compartment. The possibility of liquid or vapor damaging or corroding portions Electrical contact is significantly reduced by the construction of the heater bracket. The construction is robust and economical and results in minimal waste of liquid aerosol-forming substrate.

Claims (15)

1. A cartridge (100) for an aerosol generating system, the cartridge comprising: a storage compartment containing an aerosol-forming liquid substrate (131), the storage compartment having a first portion (130) and a second portion (135) that are connected to each other by a liquid channel such that the liquid in the first portion can pass into the second portion through the liquid channel; characterized in that the cartridge further comprises: an air flow passage (140) passing between the first portion and the second portion of the storage compartment; a fluid-permeable aerosol-generating element that is positioned between the first portion and the second portion of the storage compartment and that has a first side and a second side opposite the first side, the first side of the aerosol-generating element forming part of the airflow passage and the second side of the aerosol generating element that is in contact with the liquid in the second portion of the storage compartment, so that the aerosol-forming liquid substrate in the first portion of the storage compartment can reaching the fluid permeable aerosol generating element only through the second portion of the storage compartment. A cartridge according to claim 1, wherein the first storage compartment portion has a greater liquid storage capacity than the second storage compartment portion. A cartridge according to claim 1 or claim 2, wherein the second portion of the storage compartment contains a capillary material (136) in contact with the second side of the aerosol generating element. A cartridge according to any preceding claim, wherein the cartridge comprises a housing (105) having a connection end (115) and a muzzle-side end remote from the connection end, the connection end having is configured to connect to a control body (200) of an aerosol generating system, the second side of the aerosol generating element facing toward the connection end and the first side of the aerosol generating element facing toward the connecting end. from the side of the mouth. 5. A cartridge according to claim 4, wherein the aerosol generating element is closer to the connection end than to the mouth end opening. A cartridge according to any preceding claim, further comprising an air inlet (150) and a mouthpiece portion having an opening at the mouthside end (110), the airflow passageway being extends from the air inlet, between the first portion and the second portion of the storage compartment, to the opening at the mouthside end, where the first portion of the storage compartment is positioned between the aerosol generating element and the opening at the end of the side of the mouth. 7. A cartridge according to any preceding claim, wherein the first and second sides of the aerosol generating element are flat. A cartridge according to any preceding claim wherein the aerosol generating element comprises a plurality of interstices or openings extending from the second side to the first side and through which fluid may pass. 9. A cartridge according to any preceding claim, wherein the aerosol generating element is a heating element. A cartridge according to claim 9, comprising a heating unit (120), the heating unit comprising the heating element and electrical contact portions, electrically connecting to the heating element. 11. A cartridge according to claim 10, wherein the contact portions are exposed through a connection end of the cartridge. A cartridge according to claim 10 or 11, wherein the storage compartment comprises a heater support (134), the heater support being molded onto the heating unit. 13. An aerosol generating system comprising a cartridge according to any preceding claim and a control body (200) which is connected to the cartridge, the control body being configured to control an electrical power supply to the aerosol generating element . 14. An aerosol generating system according to claim 13, the control body comprising a pair of electrical contacts that are configured to engage electrical contact portions on the cartridge. 15. An aerosol generating system according to claim 13 or 14, wherein the aerosol generating system is a portable aerosol generating system.